Artificial flower and method of and apparatus for making the same



Sept. 15, 1936. s. H. ROGERS 2,054 605 ARTIFICIAL FLOWER AND METHOD OF AND APPARATUS FOR MAKING THE SAME Filed Aug. 1, 1954 2 Sheets-Sheet l I Ma a/rap. Snswmw b; R0606 A TT RIVE Y5 Sept. 15, 1936. I s, H R ER 2,054,605

ARTIFICIAL FLOWER AND METHOD OF AND APPARATUS FOR MAKING THE SAME Filed Aug. 1, 1934 2 Sheets-Sheet 2 Mun/r09: STEWART h. P0667178 A rroe/ve'rs Patented Sept. 15, 1936 PATENT OFFICE ARTIFICIAL FLOWER AND METHOD OF AND APPARATUS FOR MAKING THE SAME Stewart llrRogers, Pasadena, Calif.

Application August 1, 1934; Serial No. 737,888

11 Claims.

This invention, as indicated, relates to artificial flowers and method of and apparatus for making the same. More particularly, it comprises the making of the petals and other portions of a flower with thin rubber and assembling the same tostem so as to produce a complete artificial flower having very close resemblance to a natural flower.

In my PatentNo. 1,730,628, granted October 8,

1 929, I have made reference to the construction of artificial flowers and the like, having doublewalled petals adapted: to be filled with means for slightly distending the same. In such instance, the petals were formed of sheets cut to suitable 1'5 outline and united at their margins to provide the inner chamber.

The present invention has in view the molding of such double-walled petals preferably in groups and also has in view the shaping of the petals below the point where the same are visible when assembled in the flower in such manner as to provide asupport or anchorage to hold the freeend of the petal in the desired position without stiffening the petal to suchan extent that it would not closelyresemble the petal of a natural flower.

The principal object of the present invention is to provide an artificial flower or the like having all ora major portion of its parts formed of double-walled thin flexible material such as rubher and rubber compositions of various kinds, and thereafter so treating the molded body as to produce a flower having substantially the characteristics of a natural flower.

Another object of the invention is to provide double-walled flexible members forming all or a portion of a flower and providing at points interiorl'y of' such structure means to position or distend the walls so as to simulate the structure of a natural flower.

A further object of the invention is to form a double-walled structure of rubber or like material by means of forming the same in a matrix or by dipping a form in a suitable solution and thereafter forming the part or parts thereof into the finished form of flower.

Another object of the invention is to provide a method of manufacturing artificial flowers wherein all or a portion thereof is formed in a matrix or about a form dipped into a'suitable solution to simulate a flower and stripped and subsequently manipulated to simulate a naturallike in a process involving several stages, which.

may comprise forming a portion of the completed flower and stripping the same from its form and thereafter providing a support for such fabricated portion and applying further material to the support and adjacent portion of the flower'to 5 complete the same.

A further object of the invention is to provide for the fabrication of a thin-walled portion of a flower or the like by means of a mold utilizing gas pressure in the interior of the material in place of a core and uniting the flower portion so formed with a supporting and finishing portion of the structure by means of a suitable fastening medium.

Another object of the invention is'to provide for the'production of a flower by making portions thereof by means of a dipping process resulting' in a thin-double-walled structure and making other portions thereof my means of a molding or cutting and curing process and uniting the parts so formed by suitable joining means.

Other and further objects of the invention will appear in the course of the following descrip' tion.

To the accomplishment of the foregoing and related ends, said invention, then, consists of the means-and method hereinafter fully described and particularly pointed out in the claims, the annexed drawings and the following description setting forth in detail certain means and'modes embodying the invention, such 1 disclosed means and modes constituting, however, but several of the various forms in which the principle of the invention may be used.

In said annexed drawings:

Figure 1 is a perspective view showing a dipped rubber rose mounted on a porcelain form preliminary to stripping;

Figure 2 is a plan view of the rose shown in Figure 1, showing the arrangement of rose petals and draining channelways; I

Figures 3 and 4 are transverse sectional views, taken along the lines 33 and 44, shown in Figure I, looking in the direction of the arrows;

Figure 5. is an enlarged sectional view of one of the petals showing greater thickness of rubber at the tip of the petal and adjacent the base portion of the petal;

Figure'6 is a fragmentary sectional view of the petal structure shown in Figure 5 after stripping from the form, and illustrating the droop of the tip of the petal in simulation of a natural flower;

Figure 7 is a perspective view of a poppy on a porcelain formpreliminary to stripping;

Figure 8 is a plan view of the poppy illustrated in Figure '7;

Figure 9 is an enlarged fragmentary detail plan view showing the central portion of the structure illustrated in Figure 8;

Figure 10 is an enlarged fragmentary detail sectional view, taken along the line Ill-l0 shown in Figure 9, looking in the direction of the arrows;

Figure 11 is a central vertical sectional view taken through a coated form showing the method of making a single unit of a flower;

Figure 12 is a top plan view of the structure shown in Figure 11;

Figure 13 is a vertical sectional view showing a flower assembled from separate units in nested relation;

Figure 14 is a perspective View showing a thinwalled bud embodying a calyx and culot as originally formed;

Figure 15 illustrates a modified method of making a thin-walled rubber flower within a mold;

Figure 16 is a perspective view of a rose similar to that shown in Figure 1, illustrating the first step in the process of forming the stem;

Figures 17 and 18 are views similar to Figure 16 showing successive steps in the process of finishing the stem section;

Figure 19 is a perspective view, partly in section, showing one method of supplying a calyx and culot to a flower formed with a stern similar to that shown in Figure 18;

Figure 20 is a perspective view, partly in section, showing another method of adding the calyx and culot to a flower;

Figure 21 is a view similar to Figure 20 showing still another method of supplying a calyx and culot to a flower;

Figure 22 is a perspective view, partly in section, showing a thin-walled chrysanthemum with distending material inserted within the body of the same;

Figure 23 is a perspective view, partly in section, showing a thin-walled flower adapted to be telescopically engaged over a thin-walled stem embodying a calyx, culot and supporting member;

Figure 24 is a fragmentary view, partly in section, showing a thin-walled flower engaged in clamping relation with a locking groove of a solid rubber stern provided with an integral calyx and culot; and

Figure 25 is a view similar to Figure 24, showing the method of engaging a thin-walled flower with the locking groove of the structure illustrated in Figure 24.

The preferred form of my invention for flowers having relatively thin petals, includes the use of forms. which are to be dipped into a solution of rubber or rubber composition or the like. The forms may be made of various materials of suitable composition so that the rubber adhering thereto may be readily stripped therefrom. It has been found that such forms when made of porcelain serve very satisfactorily in the dipping process, but they also may be made of wood or metal or compositions of various kinds, and it is not intended to restrict the scope of this inventionto any particular material unless otherwise specified in the claims.

Dipping, may include several complete or partial immersions of the form in the solution and the solution itself maybe made very thin and fluid so as to require multiple dipping, or it may be made of a fairly heavy consistency so that a sin'gle'dipping will suffice. Likewise, the dipping may be made first in a heavier solution and later in a thinner solution or vice versa. Ordinarily the dipping of the petal tip portion of the form a. plurality of times is desirable in order that the more flexible tip portions of the structure will have a thickened marginal portion which serves as a flexible brace or reinforcing area at the points of greatest flexibility.

As is more particularly shown in the drawings, Figures 1 and 2, the molds or forms comprise a body portion I formed preferably to resemble a flower or a portion thereof and having a stem 2 formed with a hollow base member 3 adapted to engage over a pin or other suitable support. Such head portions in the forms shown are without the calyx and culot of the flower, which is preferably applied after the flower itself is finished and mounted, but where a small bud is to be formed, the calyx and culot may be formed integrally therewith, as hereinafter described.

With a form such as is illustrated in Figures 1, 7, 10 and 11, the clipping process is carried out in any desired manner. Where quantity production is in view a number of such forms are provided and mounted upon a base support which permits the entire series of forms to be dipped at one time in a suitable solution. The forms, however, may be dipped individually with equally satisfactory results.

The dipping process will result in the deposit of a thin film of rubber over the head forming a flower l6 and a portion of the stem of the form providing the stem I1, and. after the same has been cured to the desired extent, it is stripped by stretching the thin rubber member to the necessary extent to separate the form from the article. The stripping operation may be carried out by means of revolving brushes or other mechanism as may be desired, and the details thereof form no part of the present invention. When stripped from the form the article will present a flexible self-supporting structure which closely simulates the form and texture of a natural flower. In the case of large flowers, such as chrysanthemums, as illustrated in Figure 22, the

thin-walled member will not be self-supporting,

anddistending material will be inserted within the same, as will be later described.

The thin-walled member may be formed of white or light colored material and be subsequently stained or tinted by means of bristle brushes or air brushes or similar apparatus or may be formed of suitably colored rubber in the first instance. Where graduated tints are required either method may be utilized to form the flower or portions thereof.

Various ways of constructing the flowers are il lustrated, the preferred form comprising the providing of a suitable form wherein the assembled petals of the flower are formed by one or more dipping operations and wherein the escape of air to prevent the formation of air or gas pockets is provided for by means of suitable channels in the form. Thus, where the petal portion of a rose is to be formed, the porcelain head I, as shown in Figures 1 and 2, has the individual areas to form the separate petals 4 so related that a groove 5 will be formed at the base of each petal, such grooves serving as air escape channels as the form in inverted position is plunged into the reservoir containing the rubber solution. It will be noted from an inspection of Figures 5 and 6 that the thin-walled flower member 6 is not of uniform wall thickness throughout, but that the wall area 1 adjacent the base of the body portion of the flower is of greater thickness and the wall area 8 adjacentthe'tip' of'the petal portionof. the flower islikewlse of greater thickness. This increased thickness of the wall portion of thev flower much as it brings about a very natural drooping.

of the edge portion of the flower without causing the same to collapse.

The stem portion of the flower may be formed in various ways, and in order to provide for sumcient elasticity in the stem to permit it to be drawn over a widely extended head portion of the flower, the stem may be fluted or provided with tapering grooves 9, as is shown in Figure 1. The grooves h) in the form are deepest adjacent the base'of the body of the flower and taper downwardly until they merge with the outer circumference of the base portion of the mold, as is shown in Figures 1, 3 and 4. It willbe obvious that in the stripping operation an excess of circumferential stem area will be provided adjacent the base of the bud and that the stem can be stretched adistance sufflcient to fully clear the outer margins of the head portion of the form. As willlater appear, the stem portion in some instances is made use of as a support for the flower and in other instances is dispensed with altogether and a separate stem portion otherwise formed is used to mount the body portion of the flower.

The flower may be formed with a body portion providing a petal group, as illustrated in most of the figures of the drawings, or may comprise as sembled or nested individual petals or petal groups, as indicated in Figures. 11 to 13 and Figures 23 to 25. The petal groups or individual petals may be formed in substantially the shape they are to assume in the finished flower, or may be formed along lines not conforming to the finished flower shape, but in a position to curl or partially collapse after removal from the form so as to assume over a portion of their extent the desired finished form of the flower. This is illustrated in Figures 5 and 6' wherein the form shows the petal tip I'l molded at a relatively high elevation. When this portion of the flower is removed from the form, the tip portion H will assume the drooping position indicated in Figure 6.

The structure of the flower'proper, when formed as a unit or as a larger petal group, has the individual petals so arranged that adjacent petals are joined at a point inwardly of their marginal areas so as to provide a straight line of support between such points of attachment. Thus in the form shown in Figure 2 the outermost petal group comprising the petals A, B and C'. are connected to each other at the points :r, and the intermediate group of petals D, E, and F, are connected to the outermost group of petals at the points y and to each other at the points a, which are inwardly of their free marginal portions, thus providing a support or anchorage to'hold the body portions of the petal group in proper relationto each other and to permit the free marginal portions to have a degree of flexibility similar to a natural flower. The innermost petal assembly G, shown in Figure 2, isjoined in a similar manner to the intermediate petal group.

Figures 7 to 1'0 illustrate a poppy comprising a single petal group I2 wherein the petals'are connected with each other at points aspaced. in wardly from their outer margins and thus mu.- tually support each other along the lines of tension 11 indicated in dot:-and-dash in Figure 8. The petals are also supported adjacent their lower portion by means of upstanding webs l3 which have integral upwardly projecting members I4. to represent stamens, as will be noted'more particularly in Figures 7, 9 and 10. The stem 15 of the poppy illustrated in Figures 7 to 10', may bein Figures 7 and 8 may be formed of progressively smaller size so that the same could be nested, and thus produce various other types of flowers. The petal groups for nesting may have the shape shown in Figures 7 and 8' or may take the form shown in Figures 11 to 13 inclusive, wherein the individual petal groups are provided'with separated flexible marginal portions. Figure 13 illustrates an assembled flower of this character wherein a central double-walled element 2| nests.

within a cup-shaped double-walled element 22 which in turn nests within a similar cup-shaped double-walled element 23 which nests within the outermost cup-shaped double-walled element 24. Each of the inner elements 2|, 22, 23 is formed by dipping and curing upon a suitable permanent form similarly to that illustrated in Figures 11 and 12, wherein the form 25' producing the double-walled member 24 is dipped within the rubber solution and cured by well-known. methods and thereafter stripped. Vents 2B are provided near. the stem and may be cleared of rubber before stripping. The stem portion 26 of the unit in the outermost petal group 24 may be used as the means for mounting the flower while the innermost members of the. petal groups 2|, 22, 23, may have their stem portions cut away at the base of theflower element proper and thus provide openings at the base of the doublewalled members which are sealed when such members are nested, as shown in Figure 13, with their lower walls 2'! each cemented to the upper walls 28 of the respective double-walled elements. The provision'of a flower of the type just described, wherein each petal group is supported upon a lower petal group, provides for a flexibility of'support. which causes the completed flower to resemble a natural flower in the flexibility of its central and marginal portions.

In Figure 14 there is illustrated a gladiolus formed as a single unit, the stem portion 29 and flower portion 30 all made at a single dipping.

The stem portions embodies the stem proper, the calyx and culot, and may be tinted suitably to differentiate from the petal portion of the flower proper, after the thin-walled member is cured and stripped from the form.

In place of producing the petal groups or flower elements by means of a dipping operation, the double-walled structure may be formed by using a two-part mold 3| having two sections 32, 33,

- 53 formed providing a casting cavity 34, and placing a globule of gum 35 within the same with a pellet 36 of gas-forming material, which, when subjected to heat, will provide sufiicient internal pressure to distribute the film of rubber material 3'! over the interior walls of the cavity.

After stripping the petal group or flower body from the form, various methods may be utilized to complete the flower. Where a rose has been formed, as illustrated in Figures 1 and 2, the stem portion 2 may be cut into longitudinal strips 4|, as shown in Figure 16, which strips may then be twisted to provide a substantially solid spirally wound stem section 42, as shown in Figure 17, over which a cloth Wrapping 43 is applied, as shown in Figure [8. The cloth wrapping will give a substantial degree of rigidity to the stem and provide a smooth exterior for the same. A calyx 44 formed of paper or other suitable material may be engaged over the stem 43 and a culot 45 formed of wood or other suitable composition may be engaged over the stem and pressed against the calyx. The parts may be closely fitted so as to be frictionally held in substantially permanent relation, or may be secured together by some suitable adhesive or mechanical securing means.

In place of using the thin-walled stem portion of the structure to provide the permanent supporting means for the flower, the stem formed in the dipping operation may be severed adjacent the base of the flower proper and the supporting stem may be added in various ways, as shown in Figures 20 and 21.

In the form shown in Figure 20, the stem portion'of the flower 5! includes a culot 52 and calyx integrally therewith. The flower proper which is' then cemented adjacent its lower wall to the cup-shaped top wall 54 of the culot, after a rubber disk 55 has been secured within the base of the flower element to cover the aperture formed by the cutting away of the stem. The hollow stem' 5! is then engaged over a cylindrical support 56 which may be formed of wire or other suitable material.

In the form illustrated in Figure 21, a portion of the stem is rolled or curled to provide a rolled edge 6| at the base of the flower proper 62 and a stem 63 of rigid material preferably rubber with an enlarged preferably disk-like head 64 is engaged within the opening at the base of the flower by spreading the curled rim portion of the opening and snapping it over the head portion of the stem. A calyx E55 preferably formed of paper of suitable shape and color is then engaged over the stem and a culot 66 which may be formed of wood or suitable composition is engaged telescopically over the stem and pressed against the calyx. The flexible stem member may be provided with a wire 67 embedded along one side thereof and providing a member to assist in stiffening and shaping the stem as desired. The wooden culot preferably fits frictionally upon the stem but may be held in seated relation to the other elements of the flower by cement of any suitable character.

Where a large flower is to be formed, such as a chrysanthemum, in place of relying upon the internal structure of the petal assembly to support the same, the flower proper may be formed as shown in Figure 22 witha petal portion ll of substantially spherical shape and a stern portion. similar to the other flower elements heretofore described. After the flower has been cured after dipping and stripped from the form, the interior thereof is filled with loose cotton 13,

or some other light material which will serve to distend the flower without adding unduly to its weight.

In place of using cement or separate mechanical fastening means to secure the flower and stem portions together, the stem and its associated structure may be so formed that it may be engaged with the petal portion or a section of the petal portion of the flower through the elastic engagement of the parts. Thus, as shown in Figure 23, the stem 8| is formed by dipping and has an integral culot 82 and calyx 83, and also has integrally formed therewith a central flower section 84 forming the inner portion of the flower proper. The outer portion of the flower proper 85 may be formed as a double-wall petal group and be cut away adjacent its base so as to provide an opening 86 which may be engaged over a con stricted portion 81 adjacent the base of the central flower section. Thus by the mere stretching of the aperture in the base of the outer petal group sufiiciently to engage over the inner flower section, the flower may be completely assembled without the use of adhesive or separate mechanical means.

The stem and flower portions of the structure should be suitably colored to resemble a natural flower and this may be done by tinting the same after the flower elements have been formed.

In place of forming the stem over a hollow dipped section, as shown in Figure 23, it may be formed as shown in Figures 24 and. 25. In said figures a solid rubber stem 9| is shown having an integral calyx 92 and culot 93 and an extension or button portion 94 providing a circumferential groove 95 intermediate the button and the calyx. The calyx is adapted to be turned to reverse position as illustrated in Figure 25, thus opening the groove 95 to receive the marginal edges 96, 91 of the respective flower sections 98, 99 engaged upon the stem assembly. When the calyx 93 is released, it will be noted that it assumes the position shown in Figure 24, firmly holding the flower sections in clamped relation to the stem without the use of any adhesives or separate mechanical means.

It is to be understood that artificial flowers embodying different combinations of the various features shown in the difierent figures may be formed, the character of stem adopted, and the character of mounting depending in some measure upon the size of the flower and the characteristic structure of the same.

Other modes of applying the principle of my invention may be employed instead of those explained, change being made as regards the means and steps herein disclosed, provided the means and steps stated by any of the following claims or the equivalent of such stated means and steps be employed.

I therefore particularly point out and distinctly claim as my invention:

1. A method of making an artificial flower comprising the steps of forming thin double-walled elements of a flower structure by dipping a form into a rubber solution, the form difiering from the final shape of the flower as to flexible marginal portions, releasing any air beneath the rubber film, curing the rubber on said form, and thereafter stripping said form and allowing said flexible marginal portions to assume a difierent angle of repose.

2. A method of making an artificial flower-comprising the steps of forming thin double-walled elements of a flower structure by dipping a form into a rubber solution, the form differing from the final shape of the flower as to flexible marginal portions, curing the rubber on said form, thereafter stripping said form and allowing said double-walled flexible marginal portions to assume a difierent angle of repose, and uniting the several elements of the flower along lines of supp rt concealed within the structure of the flower and providing a nested relation of the parts affording natural lines of repose for the marginal portions when the thin elements are assembled in the flower structure.

3. A method of making an artificial flower which includes the steps of forming of rubber composition thin double-walled individual petal groups with openings in the base thereof, providing a stem portion of flexible material with enlarged integral elements adapted to interengage with the petal groups, assembling said petal groups in telescopic relation with said stem portion and securing the same in clamping relation to said stem.

4. A method of making an artificial flower of rubber composition which includes the steps of forming thin double-walled individual petal groups with openings in the base thereof, providing a stem portion of flexible material with clamping grooves adapted to engage the petal groups adjacent said openings, assembling said petal groups in telescopic relation with said stem portion and securing the same in clamping relation to said stem within said clamping grooves.

5. An artificial flower comprising a plurality of integral double-walled petal groups of varying sizes formed of rubber composition and assembled in nested relation, a stem formed wholly of rubber composition clampingly engaged with said petal groups, a calyx and culot formed integrally on said stem, a central extension element projecting upwardly from said stem and providing a groove intermediate the calyx and said extension element, whereby reversal of said calyx will open said groove and permit engagement of the petal groups within the same while such calyx is in reversed position and will clampingly hold the same when said calyx is restored to original position.

6. An artificial flower formed of rubber composition, having thin double-walled structural elements interconnected along lines adjacent the central portion of the structure afiording support for the upper portions of said elements.

'7. An artificial flower formed of rubber composition, having thin double-walled overlapping petal elements interconnected along lines adjacent the central inner wall portion of the structure afiording support for the upper portions of said elements.

8. An artificial flower formed of rubber composition, having thin double-walled petal elements in successive series, each individual petal element overlapping an adjacent petal element at one side margin and being overlapped by an adjacent petal element at the other side margin, and connections at such points of overlap-ping to afford support for the upper portions of said elements.

9. An artificial flower formed of rubber composition, having a plurality of thin double-walled structural elements projecting from a thin-walled hollow body portion and formed integrally throughout, and means disposed within said elements and hollow body portion to hold the same distended.

10. A form for making structural elements for artificial flowers having double-walled areas by dipping in rubber composition and stripping the film formed thereon, which comprises a member having relatively thin projecting portions shaped to resemble the flower structure with the relatively thin parts to form the free flexible marginal portions of the completed flower disposed inwardly of the normal position of said parts.

11. A form having a glazed surface for making structural elements for artificial flowers by dipping in rubber composition and stripping the film formed thereon, which comprises a member shaped to resemble the flower structure with the parts adjacent the free flexible marginal portions of the completed flower disposed inwardly of the normal position of said parts, and means to permit air pockets to be released through said form from said film.

STEWART I-I. ROGERS. 

